Foldable modular packaging, in particular for industrial products

ABSTRACT

The present invention concerns a foldable modular packaging (1), characterised in that it comprises: at least four panels (10) that can be moved between a folded position, in which the panels (10) are stacked on each other, and an unfolded position, in which the panels (10) form a parallelepiped frame (11) defining an internal volume (12); a flexible inner container (20) suitable for being arranged in said internal volume (12); and an assembly system (30) comprising linking elements (31) forming a pivot link between each panel (10) and at least one adjacent panel (10).

The present invention concerns a foldable modular packaging, notably of intermediate bulk container (IBC) type, for the packaging and protection of different products. The field of the invention is product handling, transport and storage.

In a known manner, IBCs are used for the packaging and protection of liquid, viscous or solid products, potentially with change of state and, by extension, powders and aggregates. The volumes concerned comprise the range from 50 to 1250 liters.

In practice, the packaging must preserve its integrity over time, for normal storage and transport use, associated with all the usual interior and exterior climate conditions.

The packaging which is currently available is constructed as rigid casings. It may be cylindrical or parallelepiped, in metal, sheet, or obtained by injection solutions, plastic material blowing, in order to obtain complete volume forms. It must be manufactured in specialized units, then transported and stored empty, while occupying a high volume. This, therefore, has a negative impact on the logistical chain.

After use, the end user of products packed in IBC must carry out recycling, in the regulatory sense, with this packaging being transported again almost empty, in order to 25 eliminate what is considered as waste for the whole of the hollow body. This translates to processing of all of the component materials of the packaging, with a significant amount of energy and quantities of water used. The packaging is reconditioned, with repair or renovation, to be used again. In the event of final destruction of the packaging, waste is generated from the total mass of the hollow body.

U.S. Pat. No. 5,002,194A describes a foldable modular packaging for transporting liquid. The packaging comprises six panels that can be moved between a folded position, in which the panels are stacked on each other, and an unfolded position, in which the panels form a parallelepiped frame defining an internal volume. The lower panel comprises feet. The packaging comprises a flexible inner container suitable for being arranged in the frame's internal volume. The container comprises a thin wall, so that when it is filled with liquid it cannot support itself without the frame. The container is equipped with reinforcements to support the legs of upper packaging, when several items of packaging are stacked on each other. The packaging comprises an assembly system comprising linking elements forming a pivot link between each panel and at least one adjacent panel. When the packaging is dismantled, the container fitted with reinforcements is removed by clearing one of the side panels or the upper panel. The container is not retracted between the panels in the folded position. This complicates the handling and transport of the packaging, with the frame on one side and the container fitted with reinforcements on the other side.

The aim of the present invention is to provide an improved packaging for resolving the above drawbacks.

To this end, the subject-matter of the invention is a foldable modular packaging, characterized in that it comprises: at least four panels that can be moved between a folded position, in which the panels are stacked on each other, and an unfolded position, in which the panels form a parallelepiped frame defining an internal volume; a flexible inner container suitable for being arranged in said internal volume; and an assembly system comprising linking elements forming a pivot link between each panel and at least one adjacent panel.

Thus, the invention enables to obtain multi-function, high performing and practical to use packaging, for all types of liquid, viscous or solid products, in advance of their implementation. The empty packaging volume is significantly reduced during the transport and storage in reserved space phases. Once filled, the packaging enables the properties of all of the material contained to be preserved. Consequently, the invention enables the transport and storage to be secured in all the usual situations and climate conditions encountered. The product's final geometry may be obtained manually, without tool, and with the assembled components, defining an inseparable whole.

According to other advantageous features of the invention, considered alone or in combination:

-   -   In the folded position, the flexible inner container is         retracted between the panels.     -   The panels are interchangeable.     -   The panels are identical.     -   The panels are flat.     -   The panels comprise a flat lower panel. This lower panel is         exempt of hollow or cavity, provided for example to receive the         flexible inner container when the frame is folded.     -   The linking elements form a 360 degree pivot link between each         panel and at least one adjacent panel.     -   The packaging comprises six movable panels able to form the         parallelepiped frame.     -   The packaging comprises a lower frame designed to be interposed         between a lower panel of the packaging and a standardized         handling pallet, with the frame having a lower face comprising         protruding elements which correspond in size and position to the         open spaces in the pallet.     -   In the folded position, with the flexible inner container         retracted between the panels, the packaging occupies minimum         volume, with a coverage surface strictly lower than the surface         of a standardized handling pallet.     -   The linking elements are positioned at each edge between two         adjacent panels.     -   The linking elements are composed of blade-shaped elements, each         comprising a large number of spires, with the said spires         engaging two adjacent panels in order to create a pivot link         between said panels.     -   The linking elements comprise a blade positioned at each edge         between two adjacent panels.     -   The linking elements are composed of rings which engage two         adjacent panels to create a pivot link between said panels.     -   The flexible inner container comprises means for hooking to the         frame formed by the panels.     -   The flexible inner container is airtight.     -   The flexible inner container comprises at least two layers,         including one exterior layer and at least one airtight interior         layer.     -   The flexible inner container comprises only two layers, i.e. one         exterior layer and one airtight interior layer.     -   The exterior layer is non-airtight, for example, made of fabric.     -   The exterior layer is airtight.     -   The flexible inner container comprises one non-airtight layer         and at least three airtight interior layers.     -   The flexible inner container comprises at least one opening for         filling or emptying.     -   The flexible inner container comprises an opening in the upper         part for filling and an opening in the lower part for emptying.     -   One opening in the flexible inner container is connected to the         mounting of a panel defined by its position in relation to the         internal volume.     -   The opening in the upper part is connected to the upper panel.     -   The opening in the lower part is connected to a side panel.     -   The flexible inner container lacks rigid reinforcements.     -   The assembly system comprises locking means which are able to         lock the frame in the unfolded position.     -   The locking means comprise one part with two L-shaped branches,         with the branches fitted with notches for attachment to the         panels.     -   The locking means comprise one part with a single L-shaped         branch fitted with notches for attachment to the panels.

The packaging or IBC according to the invention is significantly multi-purpose, adapted to all situations in the field of handling, storage and transport of liquid, viscous or solid-type products after state change, powders or aggregates.

According to the Applicant's experimentations, the space saved for an identical volume to be packed is a factor of 10. For example, a 100 m³ HGV truck will transport 336 equivalent 1000 liter IBC packages instead of 52. Thus, the reduction in transport volumes for recycling and conversion is also possible; this is also the case for spaces reserved for storing hollow bodies. It is important to note the reduction in the associated carbon impact.

In addition, thanks to the use of the flexible container comprising an airtight lower layer, much of the packaging may be reused for another fill, replacing only the interior layer which was in contact with the product.

Therefore, savings in volume, weight and manner, as well as significant cost reductions, are possible thanks to the invention, during all of the packaging's life phases: during handling, transport, storage and repacking.

The invention will be better understood upon reading the following description, given solely as a non-limiting example, and made with reference to the accompanying figures wherein:

FIG. 1 is a perspective view of the packaging according to the invention, in an unfolded position enabling the products to be packed;

FIG. 2 is an exploded view of the lower part of the packaging;

FIG. 3 is a perspective view of the packaging, during change to the unfolded position;

FIG. 4 is a partial cross sectional view of the lower part of the packaging;

FIG. 5 represents two side panels, which move in relation to each other;

FIG. 6 is a perspective view of the packaging in a folded position;

FIG. 7 is a perspective view of a flexible container provided to equip the packaging;

FIG. 8 is a perspective view of the packaging in an unfolded position;

FIG. 9 is a perspective view of an opening of the packaging for emptying products;

FIG. 10 is a front view of the opening in FIG. 9;

FIG. 11 is a cross sectional view along line XI-XI in FIG. 10;

FIGS. 12 and 13 represent two embodiments of the locking elements;

FIG. 14 is a perspective view of two panels connected by rings; and

FIG. 15 is a perspective view showing packaging of different sizes, laid out in different configurations.

FIGS. 1 to 13 show foldable modular packaging (1) compliant with a preferred embodiment of the invention, with its component elements.

The packaging (1) comprises six panels (10), a flexible inner container (20) and an assembly system (30).

The six panels (10) are movable between:

-   -   A folded position, in which the panels (10) are stacked on each         other, and     -   An unfolded position, in which the panels (10) form a         parallelepiped frame (11) which is cubic in form, defining a         hollow internal volume (12).

Each panel (10) is presented as a grill manufactured from metal wires. The position of the frame wires may be different, crossed or alternating. The panels (10) may be assembled by welding, with two wires in contacted according to a screen adapted to the efforts, defined by its chain and frame. The panels (10) are treated against corrosion and do not present any roughness.

Preferably, the packaging (1) comprises six panels (10), which enables a cube to be formed, closed on all its sides in the unfolded position, defining a casing.

Alternatively, it is possible to implement only five or four panels (10), to form a cube which is open on certain sides in the unfolded position.

Advantageously, the panels (10) are interchangeable. This significantly simplifies the assembly of the packaging (1). In practice, it is not necessary to find first the lower panel, then the side panels, then the upper panel, to produce this assembly using the linking elements (31).

The flexible container (20) is designed to be placed in the internal volume (12) marked by the panels (10), in unfolded or folded position.

When the packaging (1) is unfolded, the deployed container (20) presents a volume homogeneous to the volume (12) delimited by the structure of the assembled and deployed frame (11).

When the packaging (1) is folded, the container (20) is retracted between the panels (10). This significantly facilitates the handling and transport of the packaging (1), in comparison with packaging in which the folded frame and the container are separated.

The container (20) comprises at least two flexible layers, including one non-airtight or airtight exterior layer and at least one airtight interior layer.

According to a preferred embodiment, the container (20) comprises a non-airtight exterior layer, for example a fabric canvas, and an airtight interior layer.

The container (20) may be manufactured from Polyethylene (PE), Polypropylene (PP), Polyester (PET), Polyamide (PA), Aramid, fiberglass-based polymers and so on. The container (20), notably the canvas, may comprise additives which provide protection against ultraviolet radiation. The canvas may be made from woven thread and/or colored material. The component material of the interior layer is chosen to be intrinsically compatible with the packaged products.

The container (20) comprises means for hooking (21) to the frame (11) formed by the panels (10). These hooking means (21) may be fabric links, connecting the container (20) to the panels (10) with knots, enabling a complete reversible link.

The container (20) comprises means for handling (22) by an operator. These handling means (22) may be handles attached to the upper four corners of the container (20). More precisely, the handles are connected to the upper layer of the container (20).

The container (20) comprises at least one opening (24, 25) for filling or emptying products. Preferably, the container (20) comprises an opening (24) in the upper part for filling and an opening (25) in the lower part for emptying. The openings (24, 25) may be connected to the frame (11) via hooks (35).

The packaging (1) may comprise sleeve or flap-type openings to adapt the packaging (1) to the liquid or solid products. Thus, the size of the openings is adapted to the intended use. These sleeves or flaps may be connected by lace, Velcro, zip fastener, button, press button or hook-type devices and so on. The openings may be equipped with airtight opening and closing mechanisms appropriate to the packaged materials. For example, the lower opening (25) may be blocked by a valve or plug (26), as shown in FIGS. 9 to 11.

The assembly system (30) comprises linking elements (31) forming a pivot link between each panel (10) and at least one adjacent panel (10).

Preferably, the linking elements (31) form a 360 degree pivot link between adjacent panels (10). The panels (10) may pivot on the two sides and not just on one side. This makes handling the panels (10) significantly easier when assembling or disassembling the packaging (1).

In the example in FIGS. 1 to 13, each of the linking elements (31) is presented as a blade (311) comprising a plurality of spires. The spires engage two adjacent panels (10) in order to create a pivot link between the said panels (10). Preferably, a blade (311) is positioned at each edge between two adjacent panels (10). The blades (311) are made from metal wire presenting a variable diameter and number of spires. The blades (311) provide fixed but reversible multi-point links between the six panels (10). The blades (311) have dimensions adapted to this purpose. The ends of the blades (311) may be provided with stop shapes, to limit their travel along the edges between the panels (10). The blade (311) presents the advantage of forming a fixed link but one which can be removed without using tools.

Other forms of element (31) may be considered without going beyond the scope of the invention.

The assembly system (30) may comprise stiffeners (32) to fix the container (20) to the frame (11) and distribute the efforts within the packaging (1). The container (20) may present brackets (27) constituting locations to position the stiffeners (32).

The assembly system (30) may comprise reinforcements (33) between the panels (10) of the frame (11).

In the figures, the reinforcements (33) are presented as bars placed diagonally in the upper four corners of the frame (11) at the handles (22). Each reinforcement (33) is connected to two adjacent side panels (10).

Alternatively, the reinforcements (33) may be placed in the four upper corners and the four lower corners.

The assembly system (30) also comprises locking means (34) which are able to lock the frame (11) in the unfolded position.

As show in FIGS. 1, 3 and 12, these locking means (34) may comprise one part with two perpendicular branches in an L shape. This part comprises notches to work with the panel (10) wires. This part is positioned on a corner of the frame (11) and enables three adjacent panels (10) to be linked.

Alternatively, as shown in FIG. 13, these locking means (34) may comprise a part formed from a single branch comprising notches. This part is positioned on a corner or edge of the frame (11) and enables two adjacent panels (10) to be linked.

The packaging (1) comprises a lower frame (40) designed to be interposed between a lower panel (10) of the packaging (1) and a standardized handling pallet (50). The frame (40) has a lower side (41) comprising protruding elements (42) which correspond in size and position to the open spaces (51) in the pallet (50).

The assembly of the packaging (1) is summarized below:

-   -   The frame (40) is positioned on the pallet (50);     -   A lower panel (10) is fixed to the frame (40);     -   The folded, flexible container (20) is placed on the lower panel         (10);     -   The other five panels (10) are fixed to the lower panel (10) and         to each other thanks to the linking elements (31);     -   The filling opening (24) is positioned opposite the upper panel         (10) of the frame (11).

In its folded position, the packaging (1) may be easily stored and transported. The container (20) is retracted between the panels (10) so that the folded packaging (1) may be handled and transported as a single part.

To move to the unfolded position, the panels (10) of the frame (11) are expanded manually, by clockwise or anti-clockwise axial rotation (FIG. 5); this then enables each panel (10) of the frame (11) to be positioned in relation to the adjacent panels (10).

The volume marked for the panels (10) of the frame (11) at the end of the expansion is for example a polyhedron or a rectangle parallelepiped. The flexible container (20) comprising at least two layers is also unfolded in synchronization with the panels (10). The flexible container (20) is attached to the panels (10) by the number of knotted links (21) required for the total expansion of the container (20) during its unfolding.

The packaging (1) is modular, in that the panels (10), the container (20) and the frame (40) are presented as distinct modules, assembled thanks to the assembly 30 system (30).

FIG. 14 shows a variant of linking elements (31) forming a pivot link between two panels (10). The elements (31) are presented as rings (312) distributed along the hinge between the panels (10), defined by the common director between the panels (10). The rings (312) form clips which are initially open and can be closed in turn by plastic deformation along the panels (10). Once closed again, the rings (312) form loops which provide the pivot link between the panels (10).

FIG. 15 shows a plurality of packagings (1A, 1B, 1C, 1D, 1E) of different dimensions:

-   -   packaging (1A) is a rectangle parallelepiped defining a volume         of 60 liters;     -   packaging (1B) is a cube defining a volume of 120 liters;     -   packaging (1C) is a rectangle parallelepiped defining a volume         of 225 liters;     -   packaging (1D) is a cube defining a volume of 500 liters;     -   packaging (1E) is a cube defining a volume of 1000 liters.

The packaging (1A, 1B, 1C, 1D, 1E) may be positioned in different ways on the same standard pallet (50), for example a CP3 pallet 1140 mm wide and 1140 mm long, occupying a coverage surface strictly lower than that of the pallet (50).

The cube-shaped packaging (1E) corresponds to the packaging (1) in FIGS. 1 to 13, intended to be placed on its own on a standard pallet (50).

Thus, the packaging (1) may be presented in different sizes and similar or slightly different constructions, according to a range adapted to all types of application.

The invention offers a first level of modularity for the construction of each packaging (1) and a second level of modularity for the layout of different packaging (1) on a storage and transport unit, standard or not, such as a pallet (50), a container, a trailer and so on.

In practice, the packagings (1, 1A, 1B, 1C, 1D, 1E) may be configured differently from FIGS. 1 to 15 without going outside the scope of the invention, which is defined by the claims.

A variant which is not shown, the flexible inner container (20) may comprise several airtight interior layers. According to this variant, after a first product is transported, an interior layer is removed and the packaging may transport another product, without cleaning or replacement of the flexible container (20) being needed.

According to another variant which is not shown, the flexible inner container (20) may be provided with an intermediate layer forming a lining between the exterior and interior layers, in order to provide improved thermal insulation.

According to another variant which is not shown, the linking elements (31) may comprise a binding wire, laid along the hinge between two panels (10).

According to another variant which is not shown, the panels (10) may be made with a hollow profile with a different section, in metal or in all other materials.

According to another variant which is not shown, the panels (10) are identical. This simplifies their manufacture then their assembly.

According to a first embodiment, the panels (10) do not comprise holes for the openings (24, 25) of the container (20). When the container (20) is positioned in the internal volume (12), the grill in the panels (20) may be cut to adapt to the position of the openings (24, 25).

According to a second embodiment, all the panels (10) comprise holes in the center and on an edge, adapted to receive the openings (24, 25) of the container (20).

According to another variant which is not shown, the packaging (1) may lack a frame (40) for attachment to the pallet (50).

Moreover, the technical characteristics of the various embodiments and variants mentioned above can, in whole or for some of them, be combined with each other. Thus, the packaging may be adapted in terms of cost, functionalities and performance. 

1. Foldable modular packaging (1), wherein the packaging (1) comprises: at least four panels (10) which can move between: a folded position, in which the panels (10) are stacked on each other, and an unfolded position, in which the panels (10) form a parallelepiped frame (11) which, defining an internal volume (12); a flexible inner container (20) able to be placed in the said internal volume (12); and an assembly system (30) comprising linking elements (31) forming a pivot link between each panel (10) and at least one adjacent panel (10).
 2. Packaging (1) according to claim 1, wherein in the folded position, the flexible inner container (20) is retracted between the panels (10).
 3. Packaging (1) according to claim 1, wherein the panels (10) are interchangeable.
 4. Packaging (1) according to claim 1, wherein the panels (10) are flat.
 5. Packaging (1) according to claim 1, wherein the linking elements (31) form a 360 degree pivot link between each panel (10) and at least one adjacent panel (10).
 6. Packaging (1) according to claim 1, wherein the packaging (1) comprises six movable panels (10) able to form the parallelepiped frame (11).
 7. Packaging (1) according to claim 1, wherein the packaging (1) comprises a lower frame (40) designed to be interposed between a lower panel (10) of the packaging (1) and a standardized handling pallet (50), with the frame (40) having a lower face (41) comprising protruding elements (42) which correspond in size and position to open spaces (51) in the pallet (50).
 8. Packaging (1) according to claim 1, wherein in the folded position, with the flexible inner container (20) retracted between the panels (10), the packaging (1) occupies a minimum volume, with a coverage surface strictly lower than the surface of a standardized handling pallet (50).
 9. Packaging (1) according to claim 1, wherein the linking elements (31) are positioned at each edge between two adjacent panels (10).
 10. Packaging (1) according to claim 1, wherein the flexible inner container (20) is airtight.
 11. Packaging (1) according to claim 1, wherein the flexible inner container (20) comprises at least two layers, including one exterior layer and at least one airtight interior layer.
 12. Packaging (1) according to claim 1, wherein the flexible inner container (20) comprises at least one opening (24) for filling or emptying.
 13. Packaging (1) according to claim 1, wherein the flexible inner container (20) comprises at least an opening (24) in the upper part for filling and an opening (25) in the lower part for emptying.
 14. Packaging (1) according to claim 12, wherein an opening (24, 25) of the flexible inner container (20) is connected to the mounting of a panel (10) defined by the position of said panel (10) in relation to the internal volume (12).
 15. Packaging (1) according to claim 1, wherein the assembly system (30) comprises locking means (34) able to lock the frame (11) in the unfolded position.
 16. Packaging (1) according to claim 13, wherein an opening (24, 25) of the flexible inner container (20) is connected to the mounting of a panel (10) defined by the position of said panel (10) in relation to the internal volume (12). 